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By Matsumura T, Takematsu T

The Brown Coal Liquefaction Process (BCL Process) has been developed by Nippon Brown Coal Liquefaction Co., Ltd. (NBCL), and a 50-ton-per -day Pilot Plant has been partially completed and put into operation by Brown Coal Liquefac- tion (Victoria) Pty., Ltd. (BCLV) at Morwell, Victoria, Australia. This Project has been sponsored by New Energy Development Organization (NEDO), an or- ganization associated with MITI, and has been promoted as a National Project with funding by the Japanese government. This project has also been conducted as a cooperative technology de- velopment project between the Japanese and Aus -tralian governments since 1980 and has been supported by the Victorian state government and

Jan 1, 1987

By Jerome P. Downey

Technologies developed within the field of extractive metallurgy to recover, concentrate, and purify metals and industrial minerals from ores, have served as the foundation for all of the subsequent environmental remediation, materials recycling, and waste management technologies. This paper discusses the application of classical extractive engineering principles to the development of a thermal process for the recovery of mercury from solid wastes. Process development is presented as a series of logical stages, which begin with a thorough characterization of the site-specific waste, move on to bench and pilot scale testing of the process options, and end with a functional process flowsheet. This paper also presents thermodynamic data on many mercury species of interest to the minerals, power, and chemical industries. These data can be used to model the speciation and recovery of the mercury as a function of various process parameters.

Jan 1, 2003

By J. Stiksma, R. Kalanchey, M. J. Collins, G. Owusu, R. Raudsepp, K. R. Buban, L. A. Barta, L. Masters

This paper describes the results of testwork for the treatment of Ambatovy laterite by an acid pressure leach process, with recovery of the soluble nickel and cobalt values as mixed sulphide intermediate by precipitation with hydrogen sulphide, and subsequent refining of the mixed sulphide to nickel and cobalt metals. These process development studies were carried out primarily in 2004, as part of a bankable feasibility study for the Ambatovy Nickel Project.

Jan 1, 2004

"Metallurgical process development in greenfield projects must define the comminution flowsheet and establish the equipment sizes that are required to deliver the project design criteria. These are critical steps that heavily influence the financial performance of the project, requiring a detailed understanding of the ore properties of the project resources and the best practice methods to size comminution machines. This paper reviews current practices for determining the ore characteristics relevant to comminution circuit design. Particular attention is given to the design of sampling and testing programs, and the methods commonly applied to size crushers and mills for conventional size reduction applications in mineral processing. IntroductionMetallurgical process development in greenfield projects requires the selection of a comminution flow sheet and must establish the equipment sizes required to deliver the project design criteria. This necessitates a detailed understanding of the ore properties that define the project resource. For brownfield projects the same objectives may apply for plant expansions, or the project objective may be simply to define the capacity and operating cost of an existing facility for a new ore source. The process development phase in either instance will typically comprise the following key activities:• Geometallurgical classification and sampling of the ore deposit or deposits.• Determination of comminution energy requirements.• Benchmarking similar projects.• Identification of flow sheet options.• Equipment selection and sizing.This paper is concerned specifically with process development testing and will as such focus on the first two activities on the list: sampling and testing of the deposit. The discussion will focus on testwork programs to support the design of comminution circuits commonly in use in mineral processing today, specifically crusher, tumbling mill and stirred mill technologies.It is important that any testwork program is designed giving consideration to the types of flow sheets that are viable for the project, and the data that will need to be generated to support the final equipment sizing. Designing a testwork program to only provide information about one particular type of flow sheet will not allow sufficient information to be generated for a rigorous trade-off analysis of options, and may therefore preclude financial optimization of the project. Testing programs should be designed to collect sufficient data to ensure that any backtracking at a later stage to fill in missing information is minimal."

Jan 1, 2016

By A. Mezei

Samples of cobalt and bismuth concentrates produced from the NICO deposit in Northwest Territories were subjected to a comprehensive metallurgical testwork consisting of: pressure oxidation, ferric chloride leach and carbon in leach, to recover the cobalt, bismuth and gold, respectively. A specific testwork program was designed to allow for the optimization of process parameters under multiple restrictive criteria. The overall objective was to establish leaching sequences that could produce acceptable recoveries while generating environmentally disposable residues as well as solutions suitable for further processing. The recoveries for the leaching stage, under the optimum conditions, were 97% for cobalt and 95% for gold, in the case of the cobalt concentrate. The bismuth concentrate produced recoveries of 99% for bismuth, 99% for cobalt and 97% for gold, respectively

Jan 1, 1999

The original design of the Bougainville Copper Limited (BCL) concentrator took cognisance of the constraints imposed by the topography, the need to minimise capital cost, and the need to allow for plant expansion which, it was known, would be necessary to maintain copper and gold production as head grades declined.At the same time as spare slots have been taken up with additional equipment, technological innovations have been embraced whenever there appeared to be a chance of improving the productivity ofexisting equipment, or replacing it with a more efficient alternative.There are many examples of this in the BCL concentrator in the areas of process control, process design, instrumentation, materials handling, equipment design and wear part technology.Current process developments also pursue the latest technology. The development of the Omnicone crusher, flotation control, tailings water reclamation, and the variable speed gearless drive on the No. 13 mill are prime examples.

Jan 1, 1986

By Martin Banda, Gift C. Chisakuta, Moses Chabinga

KCM made a major modification to the Nchanga Tailings Leach Plant (TLP) changing the circuit from feeding post leach thickeners in parallel with leach discharge for solid ?liquid separation to a Counter Current Decantation (CCD) configuration utilising most of the existing equipment. The new circuit is aimed at improving copper recovery from approximately 70% to 79% through enhanced wash efficiency. The re-introduction of CCD circuit at elevated throughput of 46 000-tpd design was made possible due to the EIMCO E-Duc technology design which is an auto-dilution system that enhances solids settling rate. Commissioning (manual operation) which accommodated on-going operational requirements was phased and completed in January 2004. The circuit stabilised in subsequent months and in March alone an all time record copper recovery of 81.8% was achieved which contributed an extra 779 tonnes copper above the plant?s projected production plans. 100% of the project cost was paid back by end of April 2004 This paper discusses the work involved and the challenges faced during the re-commission

Jan 1, 2005

By Patrick E. Connell

During the ABM Conference of 2015 the latest design and process features of the new 3-roll RSB® generation were presented together with a unique Size Control System SCS® for a real time closed loop control to produce an extraordinary quality SBQ – day in, day out. In the past two years, Kocks has focused on improving the repeatability of the rolling process and developed technology to enhance the performance of its equipment. These developments include Fast Remote Control (FRC), Stands Adjustable Under Load (AUL) implementation of closed loop Size Control System (SCS), and finally a state of the art laser Gauge (4D Eagle) that pulls all of these developments into a complete package of quality. Gauges used in the past generally operated with the “shadow” measuring system. The latest gauge developments are based on the “light section” method. This method is more suitable to provide real time measurement parameters of the rolled bar. Placed close to the last rolling stand, the “light section” gauge is capable of measuring around the complete diameter with a clear definition of the bar stage in relation to the axes of the rolls. It is also capable of making these measurements using a very high measurement frequency. Following requirements of the market, requiring the highest gauge measuring frequencies which display the bar in the most accurate way even at the highest rolling speeds, the “4D Eagle” gauge was developed. This paper describes all the process features and parameters of this impressive and unique newly developed gauge as well as the other described technical improvements.

Oct 30, 2017

Zinc alloy castings continue to account for a very large, world-wide end-use market for zinc. However, an ever expanding multitude of other materials and processes are increasingly providing viable, cost-effective alternatives to designers, many of whom have no particular allegiance to any one industry. In order to meet this challenge, innovation of and for the zinc hot chamber pressure die casting process, in concert with sustained and inventive market development, is clearly required. While 'Quality' is now the watchword, and the goal of zero defects is being rigorously pursued, other important goals which must be addressed include net shape casting, enhanced productivity and increased energy efficiency. The paper gives an overview of several practical, process-orientated, projects designed to help achieve these goals. For example, a project designed to understand and precisely measure dimensional changes of castings with time has provided some of the critical information needed for net shape casting. A second study is looking anew at surface quality in relation to process conditions as an important step toward the goals of zero scrap rate and increased productivity. Developing the correct die casting machine parameters for achieving optimal quality and properties of zinc (ZA) die castings is a further example of research designed to benefit both the die caster and his customer, chiefly the original equipment manufacturer (OEM). A project on die soldering or galvanising in response to varying process parameters is similarly being considered in order to foster increased understanding and avoidance of problems, with a special interest in the use of special coatings. The maintenance or expansion of the future market for zinc die casting alloys also depends on design for functional applications, as an adjunct to their traditional decorative use. The role that alloys with enhanced properties can play, such as ZATEC, a new high creep resistant alloy developed specifically for elevated stress/elevated temperature applications, will be briefly discussed.

Jan 1, 1993

By A. S. Rao

In the original roast-leach-electrowin (RLE) circuit at the Chambishi Cobalt Plant, commissioned in 1978, the separation of nickel and zinc from cobalt in aqueous streams was achieved by successive stages of precipitation using lime. However, this technique was not able to meet the increasingly stringent metal quality requirements of customers whilst maintaining acceptable process recoveries. Intensive process development work was carried out and, in July 1988, an ion exchange circuit for nickel removal was commissioned using DOW XFS 4195 resin and for the first time Z.C.C.M. produced high purity cobalt metal containing less than 0.10% nickel. Following further work, a solvent extraction circuit for zinc removal, using DZEHPA, was commissioned in February 1991 in order to enhance cobalt recovery by reducing co-precipitated cobalt losses. This paper outlines the process development, design, commissioning and subsequent operation of these nickel ion exchange and zinc solvent extraction circuits.

Jan 1, 1993

By Lori Kormos, Jhonny Carrión De la Cruz, Dominic Fragomeni, Elizabeth Whiteman, Jorge Oliveira

"Process diagnosis, flowsheet design and optimisation are most effectively and efficiently achieved through the use of metallurgical testwork combined with more modern quantitative mineralogical techniques. Integration of the mineralogical data in testwork programs provides a resolution that cannot be obtained from assays alone and can direct the flow of work to result in optimized conditions more quickly than would otherwise be possible. At Xstrata Process Support (XPS), QEMSCAN (Quantitative Evaluation of Materials by Scanning Electron Microscope) and EPMA (Electron Probe Micro Analyser) information can be employed to diagnose specific issues in a plant or lab scale test and are routinely combined with other metallurgical data sets to benchmark performance, design and optimise flowsheets. Representative sampling protocols for ore bodies or test products, the use of geometallurgical unit classification and high confidence metallurgical test programs are key components of the strategy. Two case studies from Xstrata Zinc’s Antamina Mine and Concentrator in Perú, and Xstrata Nickel’s Nickel Rim South Mine in Sudbury are described to show how the use of quantitative mineralogy were used to diagnose a plant issue and how the data can be integrated into metallurgical programs to assist mineral processing engineers to design and optimise flowsheets.INTRODUCTIONOver the past decade, there has been a shift away from metallurgical testing that employs only chemical assays to quantify performance; the use of empirical observation in order to optimise a flowsheet; and the extraction of bulk samples for testing or piloting. The integration of geological information into the planning and execution of testwork programs including the use of quantitative mineralogy has improved the overall quality and predictability of metallurgical programs. At the same time, improvements to metallurgical testwork protocols such as rigorous statistical assessment of results, the use of factorially designed experimental strategies (DOE), and replicate flotation with appropriate quality controls, has improved the confidence level in these results.Process diagnosis, which utilizes quantitative mineralogy, can clearly define the root cause of the metallurgical issue. Whether used on its own to diagnose an issue or in combination with other metallurgical testwork, the use of mineralogical data has become the standard in the mining industry."

Jan 1, 2010

By T. C. Crosby

"Grinding has a marked effect on concentrator recovery and operating cost, and improved operation through automatic control can enhance plant performance. The correct application of automatic control can only be accomplished after the basic process variables and their effect on mill operation have been defined. This paper develops a control system for a closed circuit grinding system. Typical control systems, such as those for feed, water flow, level and circulating load, are discussed. A method of determining controllability, using the calculated reaction curve technique, is outlined. Various successful automatic grinding control applications are discussed and future possibilities are outlined. Although this paper primarily deals with closed wet grinding• circuits, the principles involved can be readily applied to other processes."

Jan 1, 1967

By T. C. Crosby

Grinding has a marked effect on concentrator recovery and opera- ting cost, improved operation through automatic control can enhance plant performance. The correct application of automatic control can only be accomplished after the basic process variables and their effect on mill operation have been defined. This paper develops a control system for a closed circuit grinding system. Typical control systems such as feed, water flow, level and circulating load are discussed. A method of determining controllability is outlined using the calculated reaction curve technique. Various successful methods of automatic grinding control applications are discussed and future possibilities are outlined. Although this paper primarily deals with closed circuit wet grinding circuits, the principles involved can be readily applied to other processes.

Jan 1, 1966

By Stuart K. Nicol, Malcolm D. Engel, Neville T. Moxon

Ion flotation of gold is a process continuing to be developed to selectively beneficiate dilute aurocyanide liquors using a novel surface­active complexing agent. Aeration of these liquors causes accumulation of the precious metal species in the froth concentrate produced in a flotation column. Successful development of ion flotation for concentrating solids-free liquors would offer a low--cost method for recovering specific metals from heap leach runoff or waste tailings solutions. The cost of constructing and operating a 100 tph gold ion flotation facility has been compared with the relevant carbon adsorption plant costs. Reductions in operating costs of 25% and installed capital of 40% are possible in relevant expenditure areas. For an 'average' processing plant, this equates to annual operating savings of A$ 170 000 and a capital saving of A$ 515 000, with a three-point increase in total (mine and plant) site DCF ROI. High gold inventories are eliminated and the number of processing steps is reduced. The application of gold ion flotation will initially be confined to heap leach operations in the western U.S.A., although use of the process in mine abandonment programmes elsewhere is also an area of future development.

Jan 1, 1992

By Adam J. Szladow

"INTRODUCTIONThe low calorific value and the high moisture and ash contents of run-of-mine (r.o.rn.) lignite limits the utilization of Saskatchewan lignites to thermal power plants in Saskatchewan, Manitoba and western Ontario. On the other hand, the low sulphur content and the low mining cost make lignites potentially attractive for new coal markets, if suitable processes can be found for upgrading. Economic upgrading to a higher quality fuel would make lignites more acceptable for industrial and utility boilers.This paper presents a summary of the process engineering evaluation of coal upgrading technologies conducted in support of a study of selected lignite upgrading processes. The summary presents the relative advantages and offers specific comments on the application of coal upgrading technologies for lignites. ResourcesLignite comprises the largest fossil fuel energy deposits in Saskatchewan. The total resources of immediate and future interest exceed 27 billion tonnes. The measured and indicated lignite resources of immediate interest are large enough to last for over 200 years at the current production rate of about 10 million tonnes per year (Table 1).Saskatchewan lignitedeposits are present in three different geologic formations: (I) the Ravenscrag Formation of Paleocene Age in southern Saskatchewan; (2) the Swan River Formation of Lower Cretaceous Age in central north Saskatchewan; and (3) the Judith River Formation of Upper Cretaceous Age in central west Saskatchewan. The deposits in the Swan River and Judith River Formation are not currently of economic interest.The Ravenscrag deposits are confmed to four lignite basins, namely: the Estevan, the Willow Bunch, the Wood Mountain and the Cypress basin (Fig. 1). The estimated resources of immediate interest in the four basins are over 7 billion tonnes (Table I). These resources include lignite seams at least 1.5 m thick, at depths of less than 45 m.The average quality of lignite varies relatively little between the four basins considering the distance between deposits (Table 2). There is, however, a progressive increase in moisture and ash content, and a decrease in calorific value and carbon content as one moves westward from the Estevan to Wood Mountain and Cypress basins. The Estevan area deposits are of higher rank despite the fact that they are stratigraphically younger than the Willow Bunch deposits (Cameron and Marconi, 1979).In upgrading lignite to a higher quality fuel, it is important to know not only the average proximate and ultimate analysis (Table 2) but also other lignite characteristics influencing the product quality . For example, Figure 2 shows the effect of lignite HIC ratio on the product equilibrium moisture for hydrothermal treatment of lignite. It is apparent that lignites with a higher HIC ratio, or high liptinite content yield much better quality product for the same hydrotreatment conditions. Other examples of lignite characteristics which are important in upgrading include distribution of sulphur forms and mineral matter, maceral composition and degree of surface oxidation."

Jan 1, 1989

By G. T. Adel

Hindered-bed separators are often used in the minerals processing industry to classify particles according to size and density. A new technology, known as the Eriez CrossFlow, was recently developed to overcome some of the limitations associated with hydraulic separators. The innovative feature of this unit is a novel feed presentation system that improves separation efficiency and capacity. In the present work, a detailed process engineering evaluation was conducted to determine the basis for the improved performance of this unit. The evaluation included controlled separation tests using well-characterized feeds, particle and liquid tracer experiments and mathematical modeling studies. Data obtained from this work show that the new separator is capable of maintaining good separation efficiencies at higher solid feed rates than traditional designs due to improved hydrodynamics in the separation zone. This paper reviews the operating principle of the Eriez CrossFlow separator, discusses the results of the tracer experiments and modeling studies and presents test data obtained from recent laboratory and plant trials. Key words: Size classification, CrossFlow separator, Hindered-bed separator, Hydraulic separator

Jan 1, 2003

By S. Brophy

Controlled Short Circuit ? Metal Inert Gas (CSC-MIG) welding is a process that can be referred as a "Cold Welding" technology. The CSC process is based on accurate control of the welding wire position, thus the mandatory requirement for the automation of the process. One of the main advantages of the CSC-MIG process is the rapid solidification of the deposited material, resulting in weldments displaying low porosity contents, and enabling the joining of thin sheet materials. These characteristics render this process an ideal one for freeforming of components, where rapid solidification would be efficacious. This presentation will focus on the progress made towards the freeforming of Al-based components in the NAIN laboratory at McGill University. The relationship between the filler metal used, freeforming (deposition) parameters, resulting microstructure and mechanical properties will be presented.

Jan 1, 2011

By A. Vien, A. J. Neale, B. C. Flintoff, R. P. Edwards

Froth flotation is one of the most widely used and effective processes for mineral beneficiation. First introduced in 1911, flotation technology has seen many developments over the past 80+ years. Innovations in reagent chemistry, equipment design, process analysis and process control have given design and plant engineers a powerful set of "tools" for process optimization. However, it does not follow that all flotation systems are optimized. As Klimpel observes: "The problem with the industrial flotation process is that it is relatively easy to get reasonable results, and relatively difficult to get excellent results" Klimpel (I 988). While reasonable was sufficient in the past, competitive forces will make excellent necessary in the future. Judging by the activities in many Canadian plants this transition is already underway. This paper examines the role of some of the optimization "tools" in effecting this change.

Jan 1, 1994

By R.P. Edwards, B.C. Flintoff

Froth flotation is one of the most widely used and effective processes for mineral benefication. First introduced in 1911, flotation technology has seen many developments over the past 80-plus years. Innovations in reagent chemistry, equipment design, process analysis and process control have given design and plant engineers a powerful set of "tools" for process optimization. However, it does not follow that all flotation systems are optimized. As Klimpel observes: "The problem with the industrial flotation process is that it is relatively easy to get reasonable results, and relatively difficult to get excellent results." Klimpel [1988] While reasonable was sufficient in the past. competitive forces will make excellent necessary in the future. Judging by the activities in many Canadian plants this transition is already underway.

Jan 1, 1995

By J. Herbst, J. Groppo, A. Noble, R. Q. Honaker

"Coal and coal byproducts produced annually contain a sufficient amount of rare earth elements (REEs) to meet current U.S. demand. The REEs exist in the form of minerals, ion-adsorbed elements associated with clays, and chemically bonded elements within the organic coal matrix or host mineral. Researchers at three universities collaborated to evaluate the effectiveness of existing physical and chemical concentration processes for the recovery of the REEs. The efforts found that physical separation processes can increase the total REE content in the thickener underflow material collected from a Central Appalachian coal cleaning facility from around 300 ppm to values greater than 17,500 ppm on an ash basis. Leaching followed by solvent extraction was found to be the most effective to recover the REEs from coarse middlings materials collected from multiple coal basins, as indicated by recovery values exceeding 80 percent. Based on material characterization data and process evaluations conducted for several potential feed coal sources, economic recovery of the REEs will require byproduct production of both clean coal and REE concentrate using a process flowsheet that is unique for each source. IntroductionRecent studies initiated by the National Energy Technology Laboratory showed that U.S. coals contain significant amounts of rare earth elements (REEs), suggesting that rare earth minerals (REMs) and/or REEs can be produced as byproducts (Ekmann, 2012). According to the report, the richest source of REEs is the Central Appalachian coal. At present, there are 208 coal preparation plants located in the region consisting of areas within the states of West Virginia, Kentucky, Pennsylvania, Virginia, Alabama and Tennessee, with a total capacity of 166,495 t/h, or more than 1 Gt/y (Fiscor, 2014). If only a portion of these plants are retrofitted with advanced separation processes, the U.S. coal industry would become a significant producer of REE concentrates as byproducts. An inherent advantage of becoming a byproduct producer of REEs is that no mining cost needs to be part of the production cost."

Jan 1, 2017